Mitsubishi PWFY-P36NMU-E-BU, PWFY-P36NMU-E-AU, PWFY-P36NMU-E2-AU, PWFY-P72NMU-E2-AU, PWFY-P72NMU-E-AU Service Manual
4th edition
Service Handbook
PWFY-P36NMU-E-BU / PWFY-P36, P72NMU-E(2)-AU
HWE0903C
New publication effective Aug. 2015
Specifications subject to change without notice
2015
Service Handbook
PWFY-P36NMU-E-BU
PWFY-P36, P72NMU-E-AU
PWFY-P36, P72NMU-E2-AU
Model
Service Handbook
PWFY-P36NMU-E-BU
PWFY-P36, P72NMU-E-AU
PWFY-P36, P72NMU-E2-AU
Model
www.MitsubishiElectric.com
Contents
1 Read Before Servicing ................................................................ 7
[1] Items to Be Checked .............................................................. 7
[2] Necessary Tools and Materials .............................................. 8
[3] Piping Materials ...................................................................... 9
[4] Storage of Piping .................................................................... 11
[5] Piping Processing .................................................................. 11
[6] Brazing.................................................................................... 12
[7]
Air Tightness Test
.................................................................... 13
[8] Vacuum Drying (Evacuation) .................................................. 14
[9] Refrigerant Charging .............................................................. 15
[10] Remedies to be taken in case of a Refrigerant Leak ............ 15
[11]
Characteristics of the Conventional and the New Refrigerants
.. 16
[12] Notes on Refrigerating Machine Oil........................................ 17
2 Restrictions .................................................................................. 18
[1] Types and Maximum allowable Length of Cables .................. 18
[2] Types of Switch Setting and Address Setting ........................ 19
[3] Examples of system connection ............................................ 20
[4] Restrictions on piping length .................................................. 21
3 Components of the Unit .............................................................. 22
[1] Appearance of the Components and Refrigerant Circuit........ 22
[2] Control Box ............................................................................ 23
[3] Circuit Board .......................................................................... 25
4 Remote Controller ........................................................................ 28
[1]
Functions and Specifications of MA Remote Controller
.................. 28
[2]
Interlocking Setting via the MA Remote Controller
........................ 29
5 Electrical Wiring Diagram ............................................................ 31
[1] PWFY-P36NMU-E-BU ............................................................ 31
[2] PWFY-P36, P72NMU-E/E2-AU .............................................. 32
6 Refrigerant Circuit ........................................................................ 34
[1] Refrigerant Circuit Diagram .................................................... 34
[2] Pump interlock ........................................................................ 35
[3] Functions of Principal Parts.................................................... 36
7 Control.......................................................................................... 38
[1] Dip Switch Functions and Their Factory Settings .................. 38
8 Test Run ...................................................................................... 41
[1] Check Items before Test Run.................................................. 41
[2] Test Run Method .................................................................... 41
[3] Refrigerant .............................................................................. 41
[4] Symptoms that do not Signify Problems ................................ 42
[5] Standard operation data ........................................................ 42
9 Troubleshooting ............................................................................ 43
[1] Check Code List .................................................................... 43
[2] Responding to Error Display on the Remote Controller ........ 44
[3] Troubleshooting Principal Parts .............................................. 60
[4] Maintenance .......................................................................... 74
0 LED display.................................................................................. 79
[1] LED Monitor Display .............................................................. 79
Safety Precautions
Before installing the unit, thoroughly read the following safety precautions.
Observe these safety precautions for your safety.
WARNING
This symbol is intended to alert the user to the presence of important instructions that must be followed to avoid
the risk of serious injury or death.
CAUTION
This symbol is intended to alert the user to the presence of important instructions that must be followed to avoid
the risk of serious injury or damage to the unit.
After reading this manual, give it to the user to retain for future reference.
Keep this manual for easy reference. When the unit is moved or repaired, give this manual to those who provide these
services.
When the user changes, make sure that the new user receives this manual.
WARNING
Ask your dealer or a qualified technician to install the
unit.
Improper installation by the user may result in water leakage, electric shock, smoke, and/or fire.
Do not use steel pipes as water pipes.
Copper pipes are recommended.
The water circuit should be a closed circuit.
Properly install the unit on a surface that can withstand the weight of the unit.
Unit installed on an unstable surface may fall and cause injury.
Only use specified cables. Securely connect each cable so that the terminals do not carry the weight of the
cable.
Improperly connected or fixed cables may produce heat
and start a fire.
Take appropriate safety measures against strong
winds and earthquakes to prevent the unit from falling.
If the unit is not installed properly, the unit may fall and
cause serious injury to the person or damage to the unit.
Do not make any modifications or alterations to the
unit. Consult your dealer for repair.
Improper repair may result in water leakage, electric shock,
smoke, and/or fire.
In the event of a refrigerant leak, thoroughly ventilate
the room.
If refrigerant gas leaks and comes in contact with an open
flame, poisonous gases will be produced.
Do not touch the refrigerant pipes and Water
pipes.
Improper handling may result in injury.
Properly install the unit according to the instructions
in the installation manual.
Improper installation may result in water leakage, electric
shock, smoke, and/or fire.
Have all electrical work performed by an authorized
electrician according to the local regulations and instructions in this manual, and a dedicated circuit must
be used.
Insufficient capacity of the power supply circuit or improper
installation may result in malfunctions of the unit, electric
shock, smoke, and/or fire.
Do not use refrigerant other than the type indicated in the
manuals provided with the unit and on the nameplate.
Doing so may cause the unit or pipes to burst, or result in
explosion or fire during use, during repair, or at the time of
disposal of the unit.
It may also be in violation of applicable laws.
MITSUBISHI ELECTRIC CORPORATION cannot be held
responsible for malfunctions or accidents resulting from the
use of the wrong type of refrigerant.
Before performing maintenance work, turn off the
power to both indoor and outdoor units.
- 1 -
WARNING
Securely attach the terminal block cover (panel) to the
unit.
If the terminal block cover (panel) is not installed properly,
dust and/or water may infiltrate and pose a risk of electric
shock, smoke, and/or fire.
Only use the type of refrigerant that is indicated on the
unit when installing or reinstalling the unit.
Infiltration of any other type of refrigerant or air into the unit
may adversely affect the refrigerant cycle and may cause
the pipes to burst or explode.
When installing the unit in a small room, exercise caution and take measures against leaked refrigerant
reaching the limiting concentration.
Consult your dealer with any questions regarding limiting
concentrations and for precautionary measures before installing the unit. Leaked refrigerant gas exceeding the limiting concentration causes oxygen deficiency.
Consult your dealer or a specialist when moving or reinstalling the unit.
Improper installation may result in water leakage, electric
shock, and/or fire.
After completing the service work, check for a gas
leak.
If leaked refrigerant is exposed to a heat source, such as a
fan heater, stove, or electric grill, poisonous gases may be
produced.
Do not try to defeat the safety features of the unit.
Forced operation of the pressure switch or the temperature
switch by defeating the safety features of these devices, or
the use of accessories other than the ones that are recommended by MITSUBISHI may result in smoke, fire, and/or
explosion.
Only use accessories recommended by MITSUBISHI.
Ask a qualified technician to install the unit. Improper installation by the user may result in water leakage, electric
shock, smoke, and/or fire.
Control box houses high-voltage parts.
When opening or closing the front panel of the control box,
do not let it come into contact with any of the internal components. Before inspecting the inside of the control box,
turn off the power, keep the unit off for at least 10 minutes,
and confirm that the voltage between FT-P and FT-N on
INV Board has dropped to DC20V or less. (It takes about
10 minutes to discharge electricity after the power supply is
turned off.)
- 2 -
Precautions for handling units for use with R410A
CAUTION
Do not use the existing refrigerant piping.
A large amount of chlorine that may be contained in the residual refrigerant and refrigerating machine oil in the existing piping may cause the refrigerating machine oil in the
new unit to deteriorate.
R410A is a high-pressure refrigerant and can cause the
existing pipes to burst.
Use refrigerant pipes made of phosphorus deoxidized
copper. Keep the inner and outer surfaces of the pipes
clean and free of such contaminants as sulfur, oxides,
dust, dirt, shaving particles, oil, and water.
These types of contaminants inside the refrigerant pipes
may cause the refrigerant oil to deteriorate.
Store the pipes to be installed indoors, and keep both
ends of the pipes sealed until immediately before brazing. (Keep elbows and other joints wrapped in plastic.)
Infiltration of dust, dirt, or water into the refrigerant system
may cause the refrigerating machine oil to deteriorate or
cause the unit to malfunction.
Use a small amount of ester oil, ether oil, or alkylbenzene to coat flares and flanges.
Infiltration of a large amount of mineral oil may cause the refrigerating machine oil to deteriorate.
Charge liquid refrigerant (as opposed to gaseous refrigerant) into the system.
If gaseous refrigerant is charged into the system, the composition of the refrigerant in the cylinder will change and
may result in performance loss.
Use a vacuum pump with a reverse-flow check valve.
If a vacuum pump that is not equipped with a reverse-flow
check valve is used, the vacuum pump oil may flow into the
refrigerant cycle and cause the refrigerating machine oil to
deteriorate.
Prepare tools for exclusive use with R410A. Do not use
the following tools if they have been used with the conventional refrigerant (gauge manifold, charging hose,
gas leak detector, reverse-flow check valve, refrigerant
charge base, vacuum gauge, and refrigerant recovery
equipment.).
If the refrigerant or the refrigerating machine oil left on
these tools are mixed in with R410A, it may cause the refrigerating machine oil to deteriorate.
Infiltration of water may cause the refrigerating machine
oil to deteriorate.
Gas leak detectors for conventional refrigerants will not
detect an R410A leak because R410A is free of chlorine.
Do not use a charging cylinder.
If a charging cylinder is used, the composition of the refrigerant will change, and the unit may experience power loss.
Exercise special care when handling the tools for use
with R410A.
Infiltration of dust, dirt, or water into the refrigerant system
may cause the refrigerating machine oil to deteriorate.
Only use refrigerant R410A.
The use of other types of refrigerant that contain chlorine
(i.e. R22) may cause the refrigerating machine oil to deteriorate.
- 3 -
Before installing the unit
WARNING
Do not install the unit where a gas leak may occur.
If gaseous refrigerant leaks and piles up around the unit, it
may be ignited.
Do not use the unit to keep food items, animals, plants,
artifacts, or for other special purposes.
The unit is not designed to preserve food products.
Do not use the unit in an unusual environment.
Do not install the unit where a large amount of oil or steam
is present or where acidic or alkaline solutions or chemical
sprays are used frequently. Doing so may lead to a remarkable drop in performance, electric shock, malfunctions, smoke, and/or fire.
The presence of organic solvents or corrosive gas (i.e.
ammonia, sulfur compounds, and acid) may cause gas
leakage or water leakage.
When installing the unit in a hospital, take appropriate
measures to reduce noise interference.
High-frequency medical equipment may interfere with the
normal operation of the air conditioner or vice versa.
Do not install the unit on or over things that cannot get
wet.
When the humidity level exceeds 80% or if the drainage
system is clogged, the indoor unit may drip water. Drain water is also discharged from the outdoor unit. Install a centralized drainage system if necessary.
- 4 -
Before installing the unit (moving and reinstalling the unit) and performing
electrical work
CAUTION
Properly ground the unit.
Do not connect the grounding wire to a gas pipe, water pipe,
lightning rod, or grounding wire from a telephone pole. Improper grounding may result in electric shock, smoke, fire,
and/or malfunction due to noise interference.
Do not put tension on the power supply wires.
If tension is put on the wires, they may break and result in
excessive heat, smoke, and/or fire.
Install an earth leakage breaker to avoid the risk of
electric shock.
Failure to install an earth leakage breaker may result in
electric shock, smoke, and/or fire.
Use the kind of power supply wires that are specified
in the installation manual.
The use of wrong kind of power supply wires may result in
current leak, electric shock, and/or fire.
Use breakers and fuses (current breaker, remote
switch <switch + Type-B fuse>, moulded case circuit
breaker) with the proper current capacity.
The use of wrong capacity fuses, steel wires, or copper
wires may result in malfunctions, smoke, and/or fire.
Do not spray water on the unit or immerse the air
conditioner in water.
Otherwise, electric shock and/or fire may result.
When handling units, always wear protective gloves to
protect your hands from metal parts and high-temperature parts.
Periodically check the installation base for damage.
If the unit is left on a damaged platform, it may fall and
cause injury.
Properly install the drain pipes according to the instructions in the installation manual. Keep them insulated to avoid dew condensation.
Improper plumbing work may result in water leakage and
damage to the furnishings.
Exercise caution when transporting products.
Products weighing more than 20 kg should not be carried
alone.
Do not carry the product by the PP bands that are used on
some products.
Properly dispose of the packing materials.
Nails and wood pieces in the package may pose a risk of
injury.
Plastic bags may pose a risk of choking hazard to children. Tear plastic bags into pieces before disposing of
them.
- 5 -
Before the test run
CAUTION
Turn on the unit at least 12 hours before the test run.
Keep the unit turned on throughout the season. If the unit is
turned off in the middle of a season, it may result in malfunctions.
To avoid the risk of electric shock or malfunction of the
unit, do not operate switches with wet hands.
Do not touch the refrigerant pipes with bare hands during and immediately after operation.
During or immediately after operation, certain parts of the
unit such as pipes and compressor may be either very cold
or hot, depending on the state of the refrigerant in the unit
at the time. To reduce the risk of frost bites and burns, do
not touch these parts with bare hands.
Do not operate the unit without panels and safety
guards.
Rotating, high-temperature, or high-voltage parts on the unit
pose a risk of burns and/or electric shock.
Do not turn off the power immediately after stopping
the operation.
Keep the unit on for at least five minutes before turning off
the power to prevent water leakage or malfunction.
Do not operate the unit without the air filter.
Dust particles may build up in the system and cause malfunctions.
- 6 -
[1] Items to Be Checked
1. Check the type of refrigerant used in the system to be serviced.
Refrigerant Type
Between unit and BC controller
PWFY-P36NMU-E-BU
Inside the unit
R410A
-
PWFY-P36, P72NMU-E/E2-AU
2. Check the symptoms exhibited by the unit to be serviced.
Refer to this service handbook for symptoms relating to the refrigerant cycle.
3. Thoroughly read the safety precautions at the beginning of this manual.
4. Preparing necessary tools: Prepare a set of tools to be used exclusively with each type of refrigerant.
Refer to "Necessary Tools and Materials" for information on the use of tools.(page 8)
5. Verification of the connecting pipes: Verify the type of refrigerant used for the unit to be moved or replaced.
Use refrigerant pipes made of phosphorus deoxidized copper. Keep the inner and outer surfaces of the pipes clean and free
of such contaminants as sulfur, oxides, dust, dirt, shaving particles, oil, and water.
These types of contaminants inside the refrigerant pipes may cause the refrigerant oil to deteriorate.
6. If there is a leak of gaseous refrigerant and the remaining refrigerant is exposed to an open flame, a poisonous gas
hydrofluoric acid may form. Keep workplace well ventilated.
CAUTION
Install new pipes immediately after removing old ones to keep moisture out of the refrigerant circuit.
The use of refrigerant that contains chloride, such as R22, will cause the refrigerating machine oil to deteriorate.
R410A
R134a
- 7 -
¡¡
Read Before Servicing
[2] Necessary Tools and Materials
Prepare the following tools and materials necessary for installing and servicing the unit.
To ols for use with R410A (Adaptability of tools that are for use with R22 or R407C)
1. To be used exclusively with R410A (not to be used if used with R22 or R407C)
2. Tools and materials that may be used with R410A with some restrictions
3. Tools and materials that are used with R22 or R407C that may also be used with R410A
4. Tools and materials that must not be used with R410A
Tools for R410A must be handled with special care to keep moisture and dust from infiltrating the cycle.
setoNesUslairetaM/slooT
c tnaregirfer dna noitaucavEdlofinaM eguaG harging Higher than 5.09MPa[738psi] on the
high-pressure side
igrahc tnaregirfer dna noitaucavEesoH gnigrahC ng The hose diameter is larger than the
conventional model.
Refrigerant Recovery Cylinder Refrigerant recovery
hTgnigrahc tnaregirfeRrednilyC tnaregirfeR e refrigerant type is indicated. The
cylinder is pink.
Charging Port on the Refrigerant Cylinder Refrigerant chargingThe charge port diameter is larger
than that of the current port.
tiw tinu eht fo noitcennoCtuN eralFh the pipes Use Type-2 Flare nuts.
setoNesUslairetaM/slooT
noitceted kael saGrotceteD kaeL saG The ones for use with HFC refrigerant
may be used.
retpada evlav kcehc a fi desu eb yaMgniyrd muucaVpmuP muucaV
is attached.
eht rof snoisnemid gnissecorp eralFgnissecorp eralFlooT eralF
piping in the system using the new refrigerant differ from those of R22. Refer to next page.
Refrigerant Recovery Equipment Refrigerant recovery
May be used if compatible with R410A
or R134a
setoNesUslairetaM/slooT
Vacuum Pump with a Check Valve Vacuum drying
sepip gnidneBredneB
snoisnemid gnissecorp eralf eht ylnOstun eralf gninethgiThcnerW euqroT
for pipes that have a diameter of
ø12.70 (1/2") and ø15.88 (5/8") have
been changed.
sepip gnittuCrettuC epiP
Welder and Nitrogen Cylinder Welding pipes
Refrigerant Charging Meter Refrigerant charging
kcehc level muucaVeguaG muucaV
setoNesUslairetaM/slooT
esu ot detibihorPgnigrahc tnaregirfeRrednilyC gnigrahC
- 8 -
[3] Piping Materials
1. Copper pipe materials
The distinction between O-materials (Annealed) and 1/2H-materials (Drawn) is made based on the strength of the pipes them-
selves.
O-materials (Annealed) can easily be bent with hands.
1/2H-materials (Drawn) are considerably stronger than O-material (Annealed) at the same thickness.
2. Types of copper pipes
O-material (Annealed) Soft copper pipes (annealed copper pipes). They can easily be bent with hands.
1/2H-material (Drawn) Hard copper pipes (straight pipes). They are stronger than the O-material (Annealed)
at the same radial thickness.
Maximum working pressure Refrigerant type
4.30 MPa [624psi] R410A and R134a
Do not use the existing piping!
4. Thickness and refrigerant type indicated on the piping materials
Ask the pipe manufacturer for the symbols indicated on the piping material for new refrigerant (R410A).
Select piping materials that meet the requirements set forth in ASTM.
Select piping materials that meet the requirements set forth in ASTM.
Select piping materials that meet the requirements set forth in ASTM B280.
3. Piping materials/Radial thickness
5. Flare processing
6. Flare nut
- 9 -
- 10 -
[4] Storage of Piping
1. Storage location
Store the pipes to be used indoors. (Warehouse at site or owner's warehouse)
If they are left outdoors, dust, dirt, or moisture may infiltrate and contaminate the pipe.
2. Sealing the pipe ends
Both ends of the pipes should be sealed until just before brazing.
Keep elbow pipes and T-joints in plastic bags.
The new refrigerator oil is 10 times as hygroscopic as the conventional refrigerating machine oil (such as Suniso) and, if not
handled with care, could easily introduce moisture into the system. Keep moisture out of the pipes, for it will cause the oil to
deteriorate and cause a compressor failure.
[5] Pipe Processing
Use a small amount of ester oil, ether oil, or alkylbenzene to coat flares and flanges.
Use a minimum amount of oil.
Use only ester oil, ether oil, and alkylbenzene.
- 11 -
[6] Brazing
No changes have been made in the brazing procedures. Perform brazing with special care to keep foreign objects (such as oxide
scale, water, and dust) out of the refrigerant system.
Example: Inside the brazed connection
1. Items to be strictly observed
Do not conduct refrigerant piping work outdoors if raining.
Use non-oxidized solder.
Use a brazing material (BCuP-3) that requires no flux when brazing between copper pipes or between a copper pipe and
copper coupling.
If installed refrigerant pipes are not immediately connected to the equipment, then braze and seal both ends.
2. Reasons
The new refrigerating machine oil is 10 times as hygroscopic as the conventional oil and is more likely to cause unit failure if
water infiltrates into the system.
Flux generally contains chloride. Residual flux in the refrigerant circuit will cause sludge to form.
3. Notes
Do not use commercially available antioxidants because they may cause the pipes to corrode or refrigerating machine oil to
deteriorate.
esUgnizarb rof redlos dezidixo fo esU of non-oxidized solder for brazing
- 12 -
[7] Air Tightness Test
No changes have been made in the detection method. Note that a refrigerant leak detector for R22 will not detect an R410A leak.
1. Items to be strictly observed
Pressurize the equipment with nitrogen up to the design pressure (4.15MPa[601psi]), and then judge the equipment's air tight-
ness, taking temperature variations into account.
When using refrigerant instead of a leak detector to find the location of a leak, use R410A.
Refrigerant R410A must be charged in its liquid state (vs. gaseous state).
2. Reasons
Oxygen, if used for an air tightness test, poses a risk of explosion. (Only use nitrogen to check air tightness.)
Refrigerant R410A must be charged in its liquid state. If gaseous refrigerant in the cylinder is drawn out first, the composition
of the remaining refrigerant in the cylinder will change and become unsuitable for use.
3. Notes
Procure a leak detector that is specifically designed to detect an HFC leak. A leak detector for R22 will not detect an
HFC(R410A, R407C) leak.
rotceted egakael 22Rhcrot edilaH
- 13 -
[8] Vacuum Drying (Evacuation)
1. Vacuum pump with a reverse-flow check valve (Photo1)
To prevent the vacuum pump oil from flowing into the refrigerant circuit during power OFF or power failure, use a vacuum
pump with a reverse-flow check valve.
A reverse-flow check valve may also be added to the vacuum pump currently in use.
2. Standard of vacuum degree (Photo 2)
Use a vacuum pump that attains 0.5Torr(6 5Pa) or lower degree of vacuum after 5 minutes of operation, and connect it directly
to the vacuum gauge. Use a pump well-maintained with an appropriate lubricant. A poorly maintained vacuum pump may not
be able to attain the desired degree of vacuum.
3. Required precision of vacuum gauge
Use a vacuum gauge that registers a vacuum degree of 5Torr(650Pa) and measures at intervals of 1Torr(130Pa). (A recommended vacuum gauge is shown in Photo2.)
Do not use a commonly used gauge manifold because it cannot register a vacuum degree of 5Torr(650Pa).
4. Evacuation time
After the degree of vacuum has reached 5Torr(650Pa), evacuate for an additional 1 hour. (A thorough vacuum drying re-
moves moisture in the pipes.)
Ver ify that the vacuum degree has not risen by more than 1Torr(130Pa) 1hour after evacuation. A rise by less than
1Torr(130Pa) is acceptable.
If the vacuum is lost by more than 1Torr(130Pa), conduct evacuation, following the instructions in section 6. Special vacuum
drying.
5. Procedures for stopping vacuum pump
To prevent the reverse flow of vacuum pump oil, open the relief valve on the vacuum pump side, or draw in air by loosening
the charge hose, and then stop the operation.
The same procedures should be followed when stopping a vacuum pump with a reverse-flow check valve.
6. Special vacuum drying
When 5Torr(650Pa) or lower degree of vacuum cannot be attained after 3 hours of evacuation, it is likely that water has pen-
etrated the system or that there is a leak.
If water infiltrates the system, break the vacuum with nitrogen. Pressurize the system with nitrogen gas to
0.5kgf/cm
2
G(0.05MPa) and evacuate again. Repeat this cycle of pressurizing and evacuation either until the degree of vac-
uum below 5Torr(650Pa) is attained or until the pressure stops rising.
Only use nitrogen gas for vacuum breaking. (The use of oxygen may result in an explosion.)
01041 )2otohP(H01051 )1otohP(
Recommended vacuum gauge:
ROBINAIR 14010 Thermistor Vacuum Gauge
- 14 -
[9] Refrigerant Charging
1. Reasons
R410A is a pseudo-azeotropic HFC blend (boiling point R32=-52 C[-62 F], R125=-49 C [-52 F]) and can almost be handled
the same way as a single refrigerant, such as R22. To be safe, however, draw out the refrigerant from the cylinder in the liquid
phase. If the refrigerant in the gaseous phase is drawn out, the composition of the remaining refrigerant will change and become unsuitable for use.
2. Notes
When using a cylinder with a siphon, refrigerant is charged in the liquid state without the need for turning it upside down. Check
the type of the cylinder on the label before use.
[10] Remedies to be taken in case of a Refrigerant Leak
If the refrigerant leaks out, it may be replenished. The entire refrigerant does not need to be replaced. (Charge refrigerant in the
liquid state.)
Cylinder with a siphon
etats diuqil eht ni gnigrahc tnaregirfeR.knip si A014R roloc rednilyC
Cylinder
liquid
evlaVevlaV
liquid
Cylinder
Cylinder without a siphon
- 15 -
[11] Characteristics of the Conventional and the New Refrigerants
1. Chemical property
As with R22, refrigerants R410A and R134A are low in toxicity and chemically stable nonflammable refrigerants.
However, because the specific gravity of vapor refrigerant is greater than that of air, leaked refrigerant in a closed room will
accumulate at the bottom of the room and may cause hypoxia.
If exposed to an open flame, refrigerant will generate poisonous gases. Do not perform installation or service work in a confined area.
*1 When CFC11 is used as a reference
*2 When CO
2
is used as a reference
2. Refrigerant composition
R410A is a pseudo-azeotropic HFC blend and can almost be handled the same way as a single refrigerant, such as R22. To
be safe, however, draw out the refrigerant from the cylinder in the liquid phase. If the refrigerant in the gaseous phase is drawn
out, the composition of the remaining refrigerant will change and become unsuitable for use.
If the refrigerant leaks out, it may be replenished. The entire refrigerant does not need to be replaced.
3. Pressure characteristics
R410A has slightly higher operating pressure compared with R22.
New Refrigerant (HFC type)
R410A
R32/R125
)05/05()%tw( noitisopmoC
ciportoeza-oduesPtnaregirfeR fo epyT
Refrigerant
dedulcni toNedirolhC
1A/1AssalC ytefaS
6.27thgieW raluceloM
-/4.15-)F/C( tnioP gnilioB 60.5
Steam Pressure
(25 C,MPa/77 F,psi) (gauge)
1.557/226
Saturated Steam Density
(25 C,kg/m
3
/77 F, psi)
64.0
elbammalfnoNytilibammalF
Ozone Deplet ion Coeff icient (ODP)
*1
0
Global Warming Coefficient (GWP)
*2
1730
Refrigerant Charging Method Refrigerant charging in
the liquid state
Replenishment of Refrigerant after a Refrigerant
Leak
Available
Temperature ( C/ F )
Pressure (gauge)
R410A R134a R22
MPa/psi MPa/psi MPa/psi
-20/-4 0.30/44 0.13/19 0.14/20
0/32 0.70/102 0.29/42 0.40/58
20/68 1.34/194 0.57/83 0.81/117
40/104 2.31/335 1.02/148 1.44/209
60/140 3.73/541 1.68/244 2.33/338
65/149 4.17/605 1.89/274 2.60/377
R134a
R134a
(100)
Single-
Refrigerant
Not contained
A1/A1
102.0
-26.1/-15.0
0.67/97
32.3
Non-flammable
0
1300
Liquid charging
Possible
- 16 -
- 17 -
[12] Notes on Refrigerating Machine Oil
1. Refrigerating machine oil in the HFC refrigerant system
HFC type refrigerants use a refrigerating machine oil different from that used in the R22 system.
Note that the ester oil used in the system has properties that are different from commercially available ester oil.
2. Effects of contaminants
*1
Refrigerating machine oil used in the HFC system must be handled with special care to keep contaminants out.
The table below shows the effect of contaminants in the refrigerating machine oil on the refrigeration cycle.
3. The effects of contaminants in the refrigerating machine oil on the refrigeration cycle.
Refrigerant Refrigerating machine oil
HAB
Ester oil
R134a
R410A
*1.Contaminants is defined as moisture, air, processing oil, dust/dirt, wrong types of refrigerant, and refrigerating machine oil.
stceffEsmotpmySesuaC on the refrigerant cycle
evlav noisnapxe nezorFnoitartlifni retaW
and capillary tubes
Clogged expansion valve and capillary tubes
Poor cooling performance
Compressor overheat
Motor insulation failure
Burnt motor
Coppering of the orbiting scroll
Lock
Burn-in on the orbiting scroll
Hydrolysis
Sludge formation and adhesion
Acid generation
Oxidization
Oil degradation
Air infiltration Oxidization
Infiltration of
contaminants
Dust, dirt
Adhesion to expansion valve and capillary
tubes
Clogged expansion valve, capillary tubes, and
drier
Poor cooling performance
Compressor overheat
Infiltration of contaminants into the compressor
Burn-in on the orbiting scroll
Mineral oil
etc.
Sludge formation and adhesion Clogged expansion valve and capillary tubes
Poor cooling performance
Compressor overheat
llorcs gnitibro eht no ni-nruBnoitadarged liO
Unit Unit
Unit
Remote
BC controller
controller
2-core cable
2-core cable
Remote
controller
Unit
Multiple-
core cable
BC controller
PWFY-P36NMU-E-BU
Type of cable
Cable diameter
Remarks
Transmission cables
Shielding wire (2-core)
CVVS, CPEVS or MVVS
More than 1.25 mm
2
-
MA Remote controller cables
Sheathed 2-core cable (shielded)
CVVS
0.3 ~ 1.25 mm2 (0.75 ~ 1.25 mm2)*1
Max.length: 200 m
External input
0.3 ~ 0.5 mm
2
Max.length: 100 m
External output
0.3 ~ 1.25 mm
2
Rated voltage: L1-N: 208 ~
230 V
Rated load: 0.6 A
PWFY-P36, P72NMU-E/E2-AU
Type of cable
Cable diameter
Remarks
Transmission cables
Shielding wire (2-core)
CVVS, CPEVS or MVVS
More than 1.25 mm
2
-
MA Remote controller cables
Sheathed 2-core cable (shielded)
0.3 ~ 1.25 mm2 (0.75 ~ 1.25 mm2)*1
Max.length: 200 m
External input
0.3 ~ 0.5 mm
2
Max.length: 100 m
External output
0.3 ~ 1.25 mm
2
Rated voltage: L1-N: 208 ~
230 V
Rated load: 0.6 A
*1 Connected with simple remote controller. CVVS, MVVS: PVC insulated PVC jacketed shielded control cable
CVV, MVV
: PVC insulated PVC sheathed control cable
CPEVS :
PE insulated PVC jacketed shielded communication cable
Sheathed multi-core cable (shielded)
CVVS or MVVS
Sheathed multi-core cable (shielded)
CVVS or MVVS
Sheathed multi-core cable (shielded)
CVVS or MVVS
Sheathed multi-core cable (shielded)
CVVS or MVVS
CVVS
[1] T ypes and Maximum allowable Length of Cables
1. Wiring work
(1) Notes
1) Have all electrical work performed by an authorized electrician according to the local regulations and instructions in this manual.
2) Install external transmission cables at least 5cm [1-31/32"] away from the power supply cable to avoid noise interference.
(Donot put the control cable and power supply cable in the same conduit tube.)
3) Provide grounding for the outdoor unit as required.
4) Run the cable from the electric box of the indoor or outdoor unit in such way that the box is accessible for servicing.
5) Do not connect power supply wiring to the terminal block for transmission line. Doing so will damage the electronic components on the terminal block.
6) Use 2-core shielded cables as transmission cables.
Use a separate 2-core control cable for each refrigerant system. Do not use a single multiple-core cable to connect indoor
units that belong to different refrigerant systems. The use of a multiple-core cable may result in signal transmission errors and
malfunctions.
(2) Control wiring
Types and maximum allowable length of cables
Control lines are categorized into 2 types: transmission line and remote controller line.
Use the appropriate type of cables and observe the maximum allowable length specified for a given system. If a given system
has a long transmission line or if a noise source is located near the unit, place the unit away from the noise source to reduce
noise interference.
- 18 -
™™
Restrictions
00
Main
00
Address (1) setting varies depending on the system configuration. See “[3] Examples of system connection”
section for details.
Unit or controller
Address
Setting method
setting range
Unit Main/sub units
MA remote controller
Outdoor unit
0, 01~50
(Note 1)
0, 51~100
(Note 1, 2, 3)
52~100
(Note 2, 3)
Factory
setting
Type and method of switch setting
Switch setting vary depending on the system configuration. Make sure to read “[3] Examples of system connection”
before conducting electrical work. Turn off the power before setting the switch. Operating the switch while the unit is
being powered will not change the setting, and the unit will not properly function.
Notes:
1. Address setting is not required for a single refrigerant system (with a few exception).
2. When setting the unit and outdoor auxiliary unit address to “100,” make it “50.”
3. When an address in a system overlapped with the heat source unit or BC controller (Main) address of other refrigerant system,
choose an another address within the set range that is not in use (with a few exceptions).
4. BC controller is found only in the R2 systems.
Use the address that equals the sum of the smallest indoor
unit address in the same refrigerant system and 50.
Use the address that equals the sum of the smallest
address of the indoor unit out of all the indoor units
that are connected to the BC controller and 50.
When a sub BC controller is connected, the automatic
start up function will not be available.
Auxiliary
units
BC controller (Sub)
Use the address that equals the sum of the address of the
heat source unit in the same refrigerant system and 1.
BC controller (Main)
Assign the smallest address to the indoor unit to
become the main unit within the same group, and
then use sequential numbers to assign an address
to all the indoor units in the group.
If applicable, set the sub BC controllers in an R2
system in the following order:
(1)
Indoor unit to be connected to the main BC controller
(2)
Indoor unit to be connected to No.1 sub BC controller
(3)
Indoor unit to be connected to No.2 sub BC controller
Set the address so that (1) < (2) < (3)
No address setting required. (When operating with 2 remote controllers,
the main/sub selector switch must be set.
Various start-stop controls (Unit settings)
Each unit (or group of units) can be controlled individually by setting SW 1-3 and 1-4.
(3)
Unit port switch setting (R2 series (Factory Setting: “0”))
Make the settings for the port switch that corresponds to the connected BC (Main/Sub) controller.
When more than two ports are used, make the setting on the port with a smaller port number.
(2)
Operation of the indoor unit when the operation is resumed after the unit was stopped
Function
Setting (SW1) (Note 2)
Power ON/OFF by the
plug (Note 1)
Unit will go into operation regardless of its operation status before power off
(power failure). (In approx. 5 minutes)
Unit will remain stopped regardless of its operation status before power off
(power failure).
Unit will go into operation if it was in operation when the power was turned off
(or cut off due to power failure). (In approx. 5 minutes)
34
OFF OFF
ON ON
OFF ON
(Note 1) Do not cut off power to the outdoor unit.
Cutting off the power supply to the outdoor unit will cut off the power supply to the crankcase heater and may cause the
compressor to malfunction when the unit is put back into operation.
(Note 2) Requires that the dipswitch settings for all the units in the group be made.
Automatic restoration
after power failure
- 19 -
[2] Types of Switch Setting and Address Setting
1. Switch setting
2. Address setting
• Connect the “1” and “2” on unit TB15 to a MA remote controller. (Non-polarized 2-wire)
MA Remote controller
TB02
TB15
earth cable
(shielded)
TB5
SM1M2 SM1M2
TB3
M1M2
(A) (B) (C)
(D)
(E)
(E)
1 2S
TB15TB5
SM1M2 1 2
(shielding wire)
*Refer to the outdoor unit manual for the wiring other
than the wiring in the area defined with dotted lines.
(A) Outdoor unit
(B) BC controller
(C) PWFY-P36NMU-E-BU
(D) PWFY-P36, P72NMU-E/E2-AU
(E) MA
remote controller
• DC 10 to 13 V between 1 and 2 (MA remote controller)
• The MA remote controller cannot be used at the same time or interchangeably.
Note:
Ensure that the wiring is not pinched when fitting the terminal box cover. Pinching the wiring may cut it.
Caution:
• Use wire with supplemental insulation.
• Input to TB142A, TB142B, and TB142C should not carry voltage.
• Cables from equipment connected to external input/output should have supplemental insulation.
• Use a single multiple-core cable for external input/output to allow for connection to the PG screw.
Caution:
Wire the power supply so that no tension is imparted. Otherwise disconnection, heating or fire result.
(B)
(A)
S
2
1
L1
L2
G
L1
L2
G
DC10~13V
12
AB
(C)
S
M2
M1
(D)
(E)
2
S
M2
M1
(A)
(B)
(D)
(E)
1
DC10~13V
AB
12
(C)
(A) Non-polarized
(B) TB15 (MA remote controller cables)
(C) MA remote Controller
(D) TB5 (Transmission cables)
(E) TB2 (Power supply wiring)
PWFY-P36NMU-E-BU PWFY-P36, P72NMU-E/E2-AU
- 20 -
[3] Examples of system connection
1. Connecting remote controller, indoor and outdoor transmission cabls
• Connect unit TB5 and outdoor unit TB3. (Non-polarized 2-wire (shield))
The “S” on unit TB5 is a shielding wire connection. For specifications about the connecting cables, refer to
the outdoor unit installation manual.
• Install a remote controller following the manual supplied with the remote controller.
2. System using MA remote controller
(1) In the case of single refrigerant system (Automatic address set-up)
- 21 -
[4] Restrictions on piping length
The same piping length restrictions apply as the ones that apply to the conventional indoor units.
Refer to the Service Manual that came with the outdoor unit for restrictions on piping length.
Design the water piping system so that the total amount of water in the entire system will be as
shown in the table below.
Heat exchanger assy
Pressure sensor (63LS)
Pressure switch (63H1)
Pressure sensor (63HS)
Thermistor (TH11)
Check joint
Compressor
Heat exchanger assy
Linear expansion valve
Linear expansion valve coil
(LEV2W)
Linear expansion valve
(LEV1W)
Thermistor (TH8)
Thermistor (TH6)
Thermistor (TH22)
Thermistor (TH13)
- 22 -
££
Components of the Unit
[1] Appearance of the Components and Refrigerant Circuit
< PWFY-P36NMU-E-BU >
Heat exchanger assy
Solenoid valve
Solenoid valve coil (SV)
Thermistor (TH6,TH22)
Check valve
Linear expansion valve
(LEV1Wa,b)
Thermistor (TH8,TH23)
< PWFY-P36, P72NMU-E-AU >
- 23 -
Heat exchanger assy
Linear expansion valve
(LEV1Wa,LEV1Wb)
Thermistor (TH6)
Thermistor (TH22)
Check valve (CV1)
Check valve (CV2)
Thermistor (TH8)
Thermistor (TH23)
Solenoid valve
Solenoid valve coil (SVG)
Solenoid valve
Solenoid valve coil (SVL)
Solenoid valve
Solenoid valve coil (SV1)
< PWFY-P36, P72NMU-E2-AU >
Thermistor (THHS)
INV board
Fan
Noise filter
Te r minal block
(TB2)
Te r minal block
(TB5)
Te r minal block (TB15)
Control board
Fuse
Reactor
[2] Control Box
< PWFY-P36NMU-E-BU >
- 24 -
Tr ansformer
Fuse
Control board
Te r minal block (TB5)
Te r minal block (TB15)
DSA board
Te r minal block
(TB2)
< PWFY-P36, P72NMU-E-AU >
Tr ansformer
Fuse
Control board
Te r minal block assy (TB5)
Te r minal block assy (TB15)
DSA board
Fuse
Te r minal block assy
(TB2)
< PWFY-P36, P72NMU-E2-AU >
- 25 -
TB141A
(OUT1)
TB141A, TB142A, TB142B, TB142C : Refer to 5 Electrical Wiring Diagram
TB142A
(IN1)
TB142A
(IN2)
TB142B
(IN3)
TB142B
(IN4)
TB142C
(IN5)
TB142C
(IN6)
TB142C
(IN7)
TB142C
(IN8)
TB142C
(COM
+
)
TB141B
SW5 SW1 SW3
SW2 SW4
SWU1
SWU2
CNLVC
CNLVB
CNLVA
CN2
CN4
CN52C
CN506A,B
CN501
CN507
CNAC
F01CN631CN661
(63H1)
F631SWP3SWP2SWP1CN3TLED3
LED4
LED1
CN2M
CN422
CN421
CN401
CN402
CN403
CN404
CN405
CN63LS
CN63HS
CN3A
SWU3
TB141A
(OUT2)
TB141A
(OUT3)
TB141A
(OUT4)
[3] Circuit Board
1. Main board
< PWFY-P36NMU-E-BU, PWFY-P36, P72NMU-E/E2-AU >
- 26 -
CN5
U
V
LD9
LD2
LD1
W
R
S
CN4 CN3 CN2
2. Power board
< PWFY-P36NMU-E-BU >
- 27 -
CN5
CN52C
LO
CNAC2
E3
LI
NI
E2
E1
CNAC1
NO
3. Noise filter
CN1
4. DSA
< PWFY-P36NMU-E-BU >
< PWFY-P36, P72NMU-E/E2-AU >
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